U.S. patent number 10,818,423 [Application Number 16/018,776] was granted by the patent office on 2020-10-27 for reactor having covering portions having fitting parts fitted to each other.
This patent grant is currently assigned to Fanuc Corporation. The grantee listed for this patent is FANUC CORPORATION. Invention is credited to Masatomo Shirouzu, Kenichi Tsukada, Tomokazu Yoshida.
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United States Patent |
10,818,423 |
Yoshida , et al. |
October 27, 2020 |
Reactor having covering portions having fitting parts fitted to
each other
Abstract
A reactor according to an embodiment of the present disclosure
includes a core body. The core body includes a peripheral iron core
composed of a plurality of peripheral iron core portions, at least
three iron cores coupled to the peripheral iron core portions, and
coils wound on the iron cores. Gaps are formed between one of the
iron cores and another iron core adjacent thereto, so as to be
magnetically connectable through the gaps. The reactor further
includes a plurality of covering portions each for covering each of
the coils. The covering portions adjacent in a circumferential
direction can be fitted to each other.
Inventors: |
Yoshida; Tomokazu (Yamanashi,
JP), Shirouzu; Masatomo (Yamanashi, JP),
Tsukada; Kenichi (Yamanashi, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
FANUC CORPORATION |
Minamitsuru-gun, Yamanashi |
N/A |
JP |
|
|
Assignee: |
Fanuc Corporation (Yamanashi,
JP)
|
Family
ID: |
1000005143771 |
Appl.
No.: |
16/018,776 |
Filed: |
June 26, 2018 |
Prior Publication Data
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|
|
|
Document
Identifier |
Publication Date |
|
US 20190013134 A1 |
Jan 10, 2019 |
|
Foreign Application Priority Data
|
|
|
|
|
Jul 7, 2017 [JP] |
|
|
2017-133886 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01F
27/32 (20130101); H01F 3/14 (20130101); H01F
37/00 (20130101); H01F 27/26 (20130101); H01F
27/28 (20130101) |
Current International
Class: |
H01F
27/26 (20060101); H01F 27/28 (20060101); H01F
3/14 (20060101); H01F 27/32 (20060101); H01F
37/00 (20060101) |
Field of
Search: |
;336/5,170,200,232 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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201765902 |
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Mar 2011 |
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105742038 |
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208460540 |
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2326294 |
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DE |
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DE |
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102018105659 |
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DE |
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3038117 |
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Jun 2016 |
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EP |
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3038117 |
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Sep 2017 |
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EP |
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1415209 |
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1415209 |
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49043123 |
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JP |
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02152210 |
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JP |
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H02152210 |
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Jun 1990 |
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JP |
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2000-77242 |
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Mar 2000 |
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JP |
|
2008-210998 |
|
Sep 2008 |
|
JP |
|
2008-210998 |
|
Nov 2008 |
|
JP |
|
2016127121 |
|
Jul 2016 |
|
JP |
|
2017059805 |
|
Mar 2017 |
|
JP |
|
Primary Examiner: Chan; Tszfung J
Attorney, Agent or Firm: RatnerPrestia
Claims
What is claimed is:
1. A reactor comprising a core body, wherein the core body includes
a peripheral iron core composed of a plurality of peripheral iron
core portions, at least three iron cores coupled to the peripheral
iron core portions, and coils wound on the iron cores, gaps are
formed between one of the iron cores and another iron core adjacent
thereto, so as to be magnetically connectable through the gaps, and
the reactor further includes a plurality of covering portions each
arranged to enclose and cover each of the coils, and the covering
portions adjacent in a circumferential direction can be fitted to
each other.
2. The reactor according to claim 1, wherein fitting parts of the
covering portions have a fitting structure.
3. The reactor according to claim 1, wherein fitting parts of the
covering portions have an engaging structure.
4. The reactor according to claim 2, wherein the fitting parts are
elastically deformable.
5. The reactor according to claim 1, wherein the covering portions
are made of an insulating material.
6. The reactor according to claim 1, wherein the number of the iron
cores is an integral multiple of three.
7. The reactor according to claim 1, wherein the number of the iron
cores is an even number of four or more.
8. A reactor comprising a core body, wherein the core body includes
a peripheral iron core composed of a plurality of peripheral iron
core portions, at least three iron cores coupled to the peripheral
iron core portions, and coils wound on the iron cores, gaps are
formed between one of the iron cores and another iron core adjacent
thereto, so as to be magnetically connectable through the gaps, and
a plurality of covering portions is configured to cover each of the
coils, wherein adjacent covering portions in a circumferential
direction with respect to a center of the peripheral iron core are
coupled together via first and second fitting parts located at
corners of the covering portions, wherein the first fitting part of
one covering portion receives the second fitting part of an
adjacent covering portion.
9. A reactor comprising a core body, wherein the core body includes
a peripheral iron core composed of a plurality of peripheral iron
core portions, at least three iron cores coupled to the peripheral
iron core portions, and coils wound on the iron cores, gaps are
formed between each of adjacent iron cores of the at least three
iron cores within the peripheral iron core, wherein the at least
three iron cores are magnetically connectable through the gaps, and
a plurality of covering portions is configured to cover each of the
coils, wherein adjacent covering portions in a circumferential
direction with respect to a center of the peripheral iron core are
coupled together via first and second fitting parts located at
corners of the covering portions, wherein the first fitting part of
one covering portion receives the second fitting part of an
adjacent covering portion.
Description
This application is a new U.S. patent application that claims
benefit of JP 2017-133886 filed on Jul. 7, 2017, the content of
2017-133886 is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a reactor, and more specifically,
relates to a reactor having covering portions having fitting parts
that are fitted to each other.
2. Description of Related Art
Reactors each include a plurality of iron core coils, and each iron
core coil includes an iron core and a coil wound on the iron core.
Predetermined gaps are formed between the iron cores. For example,
refer to Japanese Unexamined Patent Publication (Kokai) Nos.
2000-77242 and 2008-210998.
There are also reactors in which a plurality of iron cores and
coils wound on the iron cores are disposed inside a peripheral iron
core constituted of a plurality of peripheral iron core portions.
In the reactor, each iron core is integrated into each peripheral
iron core portion. At the center of the reactor, predetermined gaps
are formed between the iron cores adjacent to each other.
SUMMARY OF THE INVENTION
In such a reactor, the coils are attached to the iron cores in a
state of being contained in casings (hereinafter also referred to
as "covering portions"). Thus, in the production of the reactor,
when assembling the iron cores to which the coils contained in the
casings are attached, assembly position deviates. The assembly
position deviation causes an increase in manufacturing man-hour, or
an increase in difficulty in automation of the manufacturing
process.
Therefore, a reactor that does not require an increase in
manufacturing man-hour, and an increase in difficulty in automation
of the manufacturing process is desired.
A reactor according to an embodiment of the present disclosure
includes a core body. The core body includes a peripheral iron core
composed of a plurality of peripheral iron core portions, at least
three iron cores coupled to the peripheral iron core portions, and
coils wound on the iron cores. Gaps are formed between one of the
iron cores and another of the iron cores adjacent to the one of the
iron cores, so as to be magnetically connectable through the gap.
The reactor includes a plurality of covering portions each for
covering each of the coils. The covering portions adjacent in a
circumferential direction can be fitted to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features, and advantages of the present invention will
be more apparent from the following description of an embodiment
relating to the accompanying drawings. In the drawings,
FIG. 1 is a plan view of a part of a reactor according to an
embodiment;
FIG. 2A is a plan view of a part of the reactor according to the
embodiment;
FIG. 2B is a sectional view of a part of the reactor according to
the embodiment;
FIG. 3 is a plan view of covering portions, before coupling,
constituting the reactor according to the embodiment;
FIG. 4 is a plan view of a fitting portion constituting the reactor
according to the embodiment;
FIG. 5 is a plan view of a fitting portion constituting a reactor
according to a modification example of the embodiment;
FIG. 6 is a plan view of the covering portions, after coupling,
constituting the reactor according to the embodiment;
FIG. 7 is a plan view showing the step of attaching the peripheral
iron core portions to the covering portions, in the manufacturing
process of the reactor according to the embodiment; and
FIG. 8 is a plan view showing the step of assembling a plurality of
peripheral iron core portions, in a manufacturing process of a
reactor according to a modification example of the embodiment.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described below with
reference to the accompanying drawings. In the drawings, the same
components are indicated with the same reference numerals. For ease
of understanding, the scales of the drawings have been modified in
an appropriate manner.
The following description mainly describes a three-phase reactor as
an example. However, the present disclosure can be widely applied
to not only the three-phase reactor but also any multiphase reactor
that requires a constant inductance in each phase. The reactor
according to the present disclosure can be applied to various types
of equipment, as well as being applied to the primary or secondary
side of an inverter in an industrial robot or a machine tool.
FIG. 1 is a plan view of a reactor according to an embodiment. FIG.
2A is a plan view of a part of the reactor according to the
embodiment. FIG. 2B is a sectional view of a part of the reactor
according to the embodiment, taken on line A-A of FIG. 2A.
The reactor according to the embodiment includes a core body 100
that includes a peripheral iron core 1 constituted of a plurality
of peripheral iron core portions (11, 12, and 13), at least three
iron cores (101, 102, and 103), coils (21, 22, and 23), and
covering portions (31, 32, and 33). In FIG. 1, by way of example,
the reactor is a three-phase reactor, and the three peripheral iron
core portions (11, 12, and 13), the three coils (21, 22, and 23),
and the three covering portions (31, 32, and 33) are arranged in
positions rotated by 120.degree., but the present invention is not
limited to this example. However, the number of the iron cores is
preferably an integral multiple of three. In the case of the
three-phase reactor, the coil 21 may be an R-phase coil, the coil
22 may be an S-phase coil, and the coil 23 may be a T-phase coil.
The number of the iron cores may be an even number of four or
more.
The iron cores (101, 102, and 103) are provided in the peripheral
iron core portions (11, 12, and 13), respectively, inside the
peripheral iron core 1 in a radial direction. The iron cores (101,
102, and 103) are coupled to the peripheral iron core portions (11,
12, and 13). The peripheral iron core portions (11, 12, and 13) are
divided by three dividing surfaces (112, 123, and 131). The
peripheral iron core portions (11, 12, and 13) can be formed by
laminating a plurality of electromagnetic steel sheets.
Alternatively, the peripheral iron core portions (11, 12, and 13)
may be made of pressed powder compacts. Gaps are formed between one
of the iron cores (101, 102, and 103) and another iron core
adjacent thereto, so as to be magnetically connectable through the
gap.
The coils (21, 22, and 23) are wound on the iron cores (101, 102,
and 103), respectively.
In each of the coils (21, 22, and 23), a conductor is wound
helically. As the conductor, a rectangular wire, a round wire,
etc., made of a conductive material containing copper, aluminum,
magnesium, etc., can be used. As shown in FIG. 2A, an end portion
of the coil 21 can be connected to an external device as an input
terminal 211 or an output terminal 212. As shown in FIG. 2B, an
approximately rectangular space is formed inside the coil 21, and a
part of the iron core 101 is disposed in the space.
The covering portion 31 contains the coil 21. The covering portion
31 has an opening inside of which a part of the iron core 101 is
disposed. As shown in FIG. 2B, the covering portion 31 is
preferably structured so as to cover the periphery of the coil 21.
However, the covering portion 31 may have the shape of a box having
an opened top.
The covering portions (31, 32, and 33) cover the coils (21, 22, and
23), respectively. The covering portions (31, 32, and 33) are
preferably made of an insulating material. As a result, the
covering portions (31, 32, and 33) can insulate between the coils
(21, 22, and 23) and the peripheral iron core portions (11, 12, and
13). The covering portions (31, 32, and 33) may be made of a resin
material. As the resin material, a thermoplastic resin, a
thermosetting resin, etc., can be used.
As shown in FIG. 2B, an insulating member 311 may be provided on
the covering portion 31. The insulating member 311 is preferably
disposed between an inner peripheral surface of the coil 21 and the
iron core 101. The insulating member 311 is preferably integrated
into the covering portion 31. The covering portion 31 may be made
of a sheet-like insulating material.
In example shown in FIG. 2A, the covering portion 31 includes a
first fitting part 41 and a second fitting part 51. As described
later, the first fitting part 41 is fitted onto a second fitting
part of another covering portion adjacent thereto. The second
fitting part 51 is fitted into a first fitting part of another
covering portion adjacent thereto.
FIG. 3 is a plan view of the covering portions, before coupling,
constituting the reactor according to the embodiment. The covering
portions (31, 32, and 33) are characterized in that the covering
portions adjacent to each other in the circumferential direction
can be fitted to each other. First fitting parts (41, 42, and 43)
and second fitting parts (51, 52, and 53) are preferably provided
at the corners of the covering portions (31, 32, and 33) that are
close together when the covering portions (31, 32, and 33) are
annularly arranged.
In FIG. 1, the covering portions 31 and 32 are fitted at a fitting
portion 612. The covering portions 32 and 33 are fitted at a
fitting portion 623. The covering portions 33 and 31 are fitted at
a fitting portion 631. In the fitting portion 612 shown in FIG. 1,
as shown in FIG. 3, the second fitting part 51 of the covering
portion 31 may be fitted into the first fitting part 42 of the
covering portion 32. Alternatively, in the fitting portion 612, a
first fitting part of the covering portion 31 may be fitted onto a
second fitting part of the covering portion 32.
In the same manner, in the fitting portion 623 shown in FIG. 1, as
shown in FIG. 3, the second fitting part 52 of the covering portion
32 may be fitted into the first fitting part 43 of the covering
portion 33. Alternatively, in the fitting portion 623, a first
fitting part of the covering portion 32 may be fitted onto a second
fitting part of the covering portion 33.
In the same manner, in the fitting portion 631 shown in FIG. 1, as
shown in FIG. 3, the second fitting part 53 of the covering portion
33 may be fitted into the first fitting part 41 of the covering
portion 31. Alternatively, in the fitting portion 631, a first
fitting part of the covering portion 33 may be fitted onto a second
fitting part of the covering portion 31.
FIG. 4 is a plan view of a fitting portion constituting the reactor
according to the embodiment. The first fitting part (41, 42, or 43)
and the second fitting part (51, 52, or 53), which constitute the
fitting portion (612, 623, or 631), preferably have a fitting
structure. The first fitting parts (41, 42, and 43) and the second
fitting parts (51, 52, and 53) are preferably elastically
deformable, and are preferably made of, for example, a metal, a
synthetic resin, etc. By forming the first fitting parts (41, 42,
and 43) and the second fitting parts (51, 52, and 53) from an
elastically deformable material, the first fitting parts (41, 42,
and 43) and the second fitting parts (51, 52, and 53) become
detachable from each other.
FIG. 5 is a plan view of a fitting portion constituting a reactor
according to a modification example of the embodiment. A first
fitting part (401, 402, or 403) and a second fitting part (501,
502, or 503), which constitute the fitting portion (612, 623, or
631), preferably have an engaging structure. The first fitting
parts (401, 402, and 403) and the second fitting parts (501, 502,
and 503) are preferably elastically deformable, and are preferably
made of, for example, a metal, a synthetic resin, etc. By forming
the first fitting parts (401, 402, and 403) and the second fitting
parts (501, 502, and 503) from an elastically deformable material,
the first fitting parts (401, 402, and 403) and the second fitting
parts (501, 502, and 503) become detachable from each other.
FIGS. 4 and 5 show examples in which the first fitting part and the
second fitting part have different structures, but a first fitting
part and a second fitting part may have the same structure fitted
to each other.
As shown in FIG. 3, reference numerals 41, 42, and 43 indicate the
first fitting parts provided in the covering portions 31, 32, and
33, respectively. Reference numerals 51, 52, and 53 indicate the
second fitting parts provided in the covering portions 31, 32, and
33, respectively. However, this is merely an example, and the
covering portion 31 may have two first fitting parts, or two second
fitting parts. For example, when the covering portion 31 has two
first fitting parts, it is necessary that the covering portion 32
have a second fitting part in the fitting portion 612, and it is
necessary that the covering portion 33 have a second fitting part
in the fitting portion 631.
FIG. 6 is a plan view of the covering portions, after coupling,
constituting the reactor according to the embodiment. When the
covering portions (31, 32, and 33) are annularly arranged, each of
the covering portions (31, 32, and 33) is coupled to the other
covering portions adjacent thereto, at the fitting portions (612,
623, and 631).
FIG. 7 is a plan view showing the step of attaching the peripheral
iron core portions to the covering portions, in the manufacturing
process of the reactor according to the embodiment. After the
covering portions (31, 32, and 33) are coupled together, as shown
in FIG. 6, the peripheral iron core portions (11, 12, and 13) are
attached to the covering portions (31, 32, and 33), respectively,
as shown in FIG. 7. To be more specific, the iron core 101 of the
peripheral iron core portion 11 is disposed in the opening of the
covering portion 31. In the same manner, the iron core 102 of the
peripheral iron core portion 12 is disposed in the opening of the
covering portion 32. In the same manner, the iron core 103 of the
peripheral iron core portion 13 is disposed in the opening of the
covering portion 33.
By disposing the peripheral iron core portions (11, 12, and 13) in
the openings of the covering portions (31, 32, and 33), the
structure shown in FIG. 1 is obtained. In FIG. 1, the peripheral
iron core portions 11 and 12 contact each other at the dividing
surface 112. The peripheral iron core portions 12 and 13 contact
each other at the dividing surface 123. The peripheral iron core
portions 13 and 11 contact each other at the dividing surface 131.
As a result, the peripheral iron core portions 11, 12, and 13
constitute the single peripheral iron core 1.
In the above embodiment, after the covering portions are coupled
together, each of the peripheral iron core portions is attached to
each the covering portions, but the present invention is not
limited to this example. In other words, before the covering
portions are coupled, each of the covering portions is paired with
each peripheral iron core portion, and the covering portions are
thereafter coupled to assemble the reactor. FIG. 8 is a plan view
showing the step of assembling the peripheral iron core portions,
in the manufacturing process of a reactor according to a
modification example of the embodiment. First, the coils (21, 22,
and 23) are covered with the covering portions (31, 32, and 33),
respectively. Next, the covering portions (31, 32, and 33) are
attached to the iron cores (101, 102, and 103) of the peripheral
iron core portions (11, 12, and 13), respectively. Thereafter, the
peripheral iron core portions (11, 12, and 13) are moved in the
directions of the arrows of FIG. 8, the first fitting part 41 is
fitted onto the second fitting part 53, the first fitting part 42
is fitted onto the second fitting part 51, and the first fitting
part 43 is fitted onto the second fitting part 52. As a result, the
structure of FIG. 1 is obtained.
As described above, in the reactor according to the embodiment, the
peripheral iron core portions are assembled, after coupling the
covering portions, thus enabling a reduction in manufacturing
man-hour and ease of automation of the manufacturing process. Since
the first fitting parts and the second fitting parts, which are
provided in the covering portions, are fitted to each other, it is
possible to obtain the secondary effect that the increased
stiffness of the coils brings about a reduction in the influence of
magnetic vibration and a reduction in noise.
According to the reactor of the embodiment of the present
disclosure, since the casings for containing the coils are fitted
to each other in the circumferential direction, it is possible to
prevent an increase in manufacturing man-hour and an increase in
difficulty in automation of the manufacturing process.
* * * * *